Method of and machine for forming strips of material from wet mixes, including fibers



Feb. 13, 1962 A. D- SIMPSON 3,021,255 METHOD OF AND MACHINE FOR FORMINGSTRIPS OF 4 MATERIAL FROM WET MIXES, INCLUDING FIBERS 2 Sheets-Sheet 1Filed June 27, 1958 INVENTOR.

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Feb. 13, 1962 A. D. SIMPSON 3,021,255 METHOD OF AND MACHINE FOR FORMINGSTRIPS OF MATERIAL FROM WET MIXES, INCLUDING FIBERS Filed June 27, 19582 Sheets-Sheet 2 INVENTOR.

3,021,255 METHOD OF AND MACHINE FOR FORMING STRIPS F MATE FROM WETMDiES, IN- CLUDENG FIBERS Alvan D. impson, Plainfield, N..I., assignorto The Forming Machine Company of America, Inc, Bound Brook, N.J., acorporation of Delaware Filed June 27, 1958, Ser. No. 744,940 7 Claims.(Cl. 162-156) This invention relates in general to the formation ofstrips of compositions of matter including fibers, for example, mixturesof glass fibers or filaments and synthetic resinous materials such asvinyl compounds; and more particularly the invention is directed to theproduction of such strips from mixes including a fibrous material suchas glass fibers and a liquid such as Water, with or without othermaterials such as synthetic resinous compositions.

It is desirable that strips of material of this nature shall have thefibers matted in or extending in different directions in relativelyoverlapping or overlying relation, but it has been found that inattempting to produce such strip material from wet mixes, the fibers,and particularly glass fibers, tend to attract and adhere to each otherin side by side relation and extend in the same general direction.Furthermore, the difficulty is aggravated by attempting to pass the mixthrough pipes or pumps or beaters because the fibers tend to fiocculateand prevent the formation of a strip in which the fibers are uniformlydistributed.

A primary object of the present invention is to provide a novel andimproved method and machine or apparatus for forming strips of materialof the general nature described from wet mixes comprising fibers andliquids wherein the fibers shall be matted or disposed in crossed andoverlapping relation to each other throughout the strip.

The invention also contemplates the formation of such a strip of fibrousmaterial by depositing the solid material or fibers from the mix on aforaminous wall or screen, for example, as shown in my Patents No.2,581,210 and No. 2,737,858; and another object of the invention is toprovide a novel and improved method and means of forming the mix andfeeding it to the forming screen with the fibers, particularly glassfibers, distributed haphazardly or in crisscross relation to each otherthroughout the mix.

A further object is to provide such a method and machine for feeding thefibers into the liquid in such a manner that the fibers are thoroughlydispersed or distributed at random throughout the mix and the mix shallbe quickly fed to the point of deposit, such as a form screen, with aminimum of disturbance of the mix such as might be caused by strongcurrents or movement of the mix under pressure around sharp bends orthrough pumps.

Still another object of the invention is to provide apparatus forforming and feeding a wet mix, including glass fibers, which shall bedevoid of pumps, mechanical agitators, long pipe runs and highvelocities, and sharp turns in the flow of the mix to the formingelement, whereby the tendency of the glass fibers to bunch up or sticktogether in parallel relation to each other or to fiocculate, isminimized.

Other objects, advantages, and results of the invention will be broughtout by the following description in conjunction with the accompanyingdrawings in which FIGURE 1 is a partial side elevation and partialvertical sectional view of a machine for carrying out or practicing theinvention;

' FIGURE 2 is a fragmentary transverse, vertical sectional view on theplane of the line 2-2 of FIGURE 1;

Stars act FIGURE 3 is a horizontal sectional view on the plane of theline 33 of FIGURE 2; and

FIGURE 4 is a view similar to FIGURE 1 showing a modification of theinvention.

Specifically describing the embodiment of the invention illustrated inFIGURES 1 to 3 inclusive, I have shown a forming machine A of the sametype as that disclosed in my Patent No. 2,581,210, which includes a tankin which is rotatably mounted about a horizontal axis, a hollowcylindrical rotor drum B carried by hollow trunnions 2 which arejournaled in any suitable manner, for example, in bearings 2a, and aredriven by any suitable source of power. The drum has a foraminous orscreen-like peripheral wall 3 and is located in the tank so that thelower portion thereof will be submerged in the mix 4 that is disposed atthe lower portion of the tank and fiows into the tank by gravity throughan inlet pipe 5. Upon rotation of the drum in the direction indicated bythe arrow in FIGURE 1, the liquid from the mix 4 will flow through theinterstices in the screen 3 so as to cause a depositt of some of thefibers from the mix on the screen, and as the drum continues to rotate,this deposited solid matter is elevated out of the mix to the upperportion of the tank, which provides an upper chamber where the liquiddrains from the deposited layer 6 downwardly into the drum from whencethe liquid is drained off in any suitable manner as by suction pipes 7extending into the drum through the hollow trunnions.

The deposited layer 6 is removed from the tank through an opening 8 inthe wall of the tank above the level of the mix, and the spaces betweenthe drum and the Walls of the tank at the edges of the opening aresuitably sealed, for example, by means shown in my Patent No. 2,723,599. For illustration, I have shown a roller 9 at each end of theopening journaled in the tank which is contacted by a rubber strip 10.

Gas under pressure in excess of atmospheric pressure is supplied to thetank A above the level of the mix, for example, from a suitable pumpthrough a pipe 11, and this pressure will be continuously exerted on thesurface of the mix tending to accelerate the fiow of liquid from the mixthrough the drum and at the same time force the liquid from thedeposited layer 6 on the upper portion of the drum.

This forming machine is simply illustrative of any suitable apparatusfor handling the wet mix 4, and the invention is directed to the methodand means for forming the mix and feeding it to the forming machine orother point at which the mix is to be operated upon.

As hereinbefore pointed out, the invention especially contemplates wetmixes, including glass fibers and filaments dispersed and suspended in aliquid. In accordance with the invention, short lengths of dry glassfibers or filaments are dropped in haphazard or random manner into theliquid of the mix and the mix is quickly conducted to the formingelement with a minimum of agitation of the mix.

As shown in FIGURE 1, the glass fiber may be pro vided in spools C thatmay be journaled in any suitable manner, for example, on spindles 12 ona fixed support.- ing bracket 13. One or more spools may be utilized andthe fibers therefrom may be passed through guides 14 and between feedingrollers 15 and 16 which pull the fibers between them from the spools Cand one of which cooperates with a cutter roller 17 for cutting orbreaking the fibers into short lengths or pieces 18. The fiber cuttingmechanism may be of any suitable form, but as shown, the roller 17 hasblades 19 between which and the periphery of the roller 16, the fibersare cut or broken. As shown, the roller 17 is driven from a suitablesource through a shaft 20 and the rollers 15 and 16 are driven from saidshaft from a suitable gear train 21. It will be noted that the shortlengths of the fibers 18 leave the cutter in a haphazard manner and fallby gravity freely through the atmosphere into the liquid 22 of the mixwhich is contained in a tank 23 on which the fiber cutting mechanism andthe guide 14 may be mounted for convenience above the liquid level ofthe mix. The fibers thus fall into the liquid and extend in differentdirections in crisscross or overlapping relation to each other. In somecases it may be desirable to provide a plurality of perforated pipes 24near the bottom of the tank through which compressed air is forced toagitate the mix in the tank. The bottom of the tank has an outletopening 25 connected to a pipe 26 through which the mix is conducted tothe inlet of the forming machine. Pipe 26 may serve as a standpipe toprovide a static head pressure on the mix 4 in the tank, the length ofthe pipe being varied to provide the desired pressure.

The fibers remain thoroughly and uniformly dispersed at randomthroughout the mix and are deposited on the screen 3 in crisscross oroverlapping relation to each other so as to produce the layer or strip 6in which the fibers are matted; and the excess liquid is forced from thelayer by the compressed air that enters the upper portion of the tankthrough the pipe 11. Pressure rollers 28 may be used to smooth andcompact the deposited layer.

The liquid to form the mix may be supplied to the tank 23 in anysuitable manner, but as shown, a manifold pipe 29 is provided and has aplurality of branch outlets 30 spaced longitudinally thereof so thattheir lower ends may distllharge liquid from the pipe 29 continuouslyinto the tan Other fibers may also be supplied to the mix in anysuitable manner, for example, through a manifold pipe 31- having branchoutlets 32 for discharging the fibers into the mix.

A modification of the invention is illustrated by FIG- URE'4. Here theglass fibers are pre-cut into short lengths 33 and deposited into ahopper 34 at the lower end of which is an outlet opening 35 beneathwhich is a guide plate or chute 36, the discharge end of which extendsinto a fiber distributing chamber 37. Beneath the discharge end of theplate 36 is a fiber distributor that is shown in the form of a shaft 38rotatably mounting in the chamber walls and having a plurality of plates39 projecting radially therefrom so that the fibers, as they drop bygravity from the plate 36, will fall onto the distributor and be whirledor thrown in various directions by the fiber distributor which isrotated by any suitable means in the direction of the arrow in FIGURE 4.

Preferably, the hopper and plate 36 will be constantly vibrated duringoperation of the machine, for example, by a well-known type ofelectrical vibrator 40 attached to the plate.

Preferably, the vanes or plates 39 of the fiber distributor will beformed of resilient material or covered by resilient material such asrubber so as to prevent any damage to the glass fibers.

In accordance with the invention, the dry fibers fall by gravity fromthe distributor 38, 39 freely through the atmosphere into the liquid 41of the mix before the mix passes to the forming machine D. As shown, thelower end of the distributing chamber 37 is open and connected to ahorizontal conduit 42 through which flows the liquid of the mix from anysuitable supply. The horizontal conduit isconnected to the upper end ofa standpipe 43, the lower end of which is connected to a tank 44 of theforming machine D which as shown is of the type described in my PatentNo. 2,737,858. The standpipe 43 may be of any suitable length or height,for example, feet to feet, and the mix is deposited under the statichead pressure from the lower open end of the tank D onto a formingscreen 45 which continuously moves in its own plane upon any suitablesupport and by any suitable means such f. as shown in said Patent No.2,737,858. The lower edges of the tank surrounding the open end thereofhave attached thereto suitable sealing means 46, for example, such asthe sealing means shown in said patent.

The fibers are deposited on the screen 45 and form a strip or mat E inwhich the fibers are uniformly distributed in overlapping, crisscrossedor interlaced relation to each other, and, of course, where othermaterial such as synthetic resins are included in the mix, the fiberswill be coated with such materials.

In some cases, it may be desirable to provide a water shower in the formof a perforated pipe 47 for directing a spray of water onto the surfaceof the mix to cause any floating fibers to sink into the mix.

An important feature of the invention is that it has been found that alarge quantity of water in the mix tends to prevent the glass fibersfrom sticking together or gathering in bunches or clusters, and therapid conduction of the mix to the forming screen through the straightstandpipe without turbulence, causes the glass fibers to remainseparated and uniformly dispersed in crisscross relation during thetravel of the mix to the screen and throughout the mat or strip that isdeposited on the screen.

Where large quantities of water are used in the mix, it may be desirableto form the strip or mat of material in a machine of the type shown inFIGURE 24 of my Patent No. 2,581,210 or by my pending application,Serial Number 740,377, filed June 6, 1958, so that the water that passesthrough the screen into the drum may be more v freely drained away fromthe drum than is possible by the drain pipe construction shown in FIGURE1 of the present application.

It will be understood by those skilled in the art that after fiberstrips of the nature described have been deposited on the formingelement, the strips may be dried or otherwise treated, depending uponthe compositions of the strips. For example, the strips may be heated orotherwise treated to cause proper bonding of resinous material with thefibers.

To avoid circumlocution, the term glass fibers is used in thespecification and following claims to include all fibers that have thesame general characteristics as glass fibers when mixed in a liquid withrespect to the tendency to attract each other in side by side relationand to fiocculate.

It should be understood that while I have shown and described the nowpreferred method and types of apparatus in accordance with theinvention, the steps of the method may be modified and changed and themethod may be carried out by other types of apparatus within the spiritand scope of the invention.

What I claim is:

1. A method of forming on a screen a mat from a wet mix including aliquid and glass fibers suspended therein, said method including thesteps of gravitationally dropping a multitude of short dry glass fibershaphazardly freely through the atmosphere into a body of liquid with thefibers pointing lengthwise in diiferent directions, conducting theresnltant mix with minimum turbulence to one side of said screen andcausing the liquid from the mix to flow through the screen and depositsaid fibers in crisscross relation to each other on said screen inmatted condition.

2. A method as defined in claim 1 with the additional step of sprayingliquid on the surface of said body of liquid to cause said fibers tosink into the body of liquid.

3. A method as defined in claim 1 with the additional step of injectingair jets into said body of liquid at the bottom thereof to gentlyagitate the fibers and prevent flocculation thereof.

4. A method of forming on a screen a mat from a wet mix including aliquid and glass fibers suspended therein, said method including thesteps of gravitationally dropping a multitude of short dry glass fibershaphazardly freely through the atmosphere into a body of liquid at apoint substantially higher than said screen With the fibers pointinglengthwise in different directions, causing the mix so formed to descendby gravity with minimum turbulence into contact with one side of saidscreen and causing the liquid from the mix to flow through the screenand deposit said fibers in crisscross relation to each other on saidscreen in matted condition.

5. A method of forming on a screen a mat from a wet mix including aliquid and glass fibers suspended therein, said method including thesteps of gravitationally dropping a multitude of short dry glass fibershaphazardly freely through the atmosphere into a body of liquid at apoint substantially higher than said screen with the fibers pointinglengthwise in diiferent directions, causing the mix so formed to descendby gravity through a substantially straight conduit in contact with oneside of said screen and causing the liquid from the mix to flow throughthe screen and deposit said fibers in crisscross relation to each otheron said screen in matted condition.

6. A method of forming on a screen a mat from a wet mix including aliquid and glass fibers suspended therein, said method including thesteps of gravitationally dropping a multitude of short dry glass fibershaphazardly freely through the atmosphere into a body of liquid with thefibers pointing lengthwise in different directions, conducting theresultant mix to one side of said screen while maintaining said fibershaphazardly dispersed throughout the liquid and causing the liquid fromthe mix to fiow through the screen and deposit said fibers in crisscrossrelation to each other on said screen in matted condition.

7. Apparatus for forming a mat of material from a Wet mix including aliquid and glass fibers suspended therein, said apparatus including acontainer for liquid, means above the liquid level in said container forfreely gravitationally dropping a multitude of glass fibers in separatedry condition through the atmosphere haphazardly and pointing indifferent directions into liquid in said container to form a wet mix,the container being of uniform cross-sectional area above the liquidlevel providing for unrestricted falling of the fibers from said meansto the surface of the liquid a forming screen below said container and asubstantially straight conduit extending downwardly from said containerfor conducting said mix from said container by gravity to said formingscreen so that said fibers remain haphazardly dispersed throughout saidmix.

References Cited in the file of this patent UNITED STATES PATENTS1,708,724 Haug Apr. 9, 1929 1,799,685 Grninder Apr. 7, 1931 1,870,971Sundstrom et al. Aug. 9, 1932 1,996,082 Powell Apr. 2, 1935 2,723,599Simpson Nov. 15, 1955 2,762,081 Vivian Sept. 11, 1956 2,767,091 Hill eta1 Oct. 16, 1956 2,787,542 Labino Apr. 2, 1957

1. A METHOD OF FORMING AN A SCREEN A MAT FROM A WET MIX INCLUDING ALIQUID AND GLASS FIBERS SUSPENDED THEREIN, SAID METHOD INCLUDING THESTEPS OF GRAVITATIONALLY DROPPING A MULTITUDE OF SHORT DRY GLASS FIBERSHAPHAZARDLY FREELY THROUGH THE ATMOSPHERE INTO A BODY OF LIQUID WITH THEFIBERS POINTING LENGTHWISE IN DIFFERENT DIRECTIONS, CONDUCTING THERESULTANT MIX WITH MINIMUM TURBULENCE TO ONE SIDE OF SAID SCREEN ANDCAUSING THE LIQUID FROM THE MIX TO FLOW THROUGH THE SCREEN AND DEPOSITSAID FIBERS IN CRISSCROSS RELATION TO EACH OTHER ON SAID SCREEN INMATTED CONDITION.